Device for delivering a volatile fluid to the atmosphere

ABSTRACT

A device for delivering a volatile fluid in a continuous manner, over a period of time and without leakage, is disclosed. The device includes a flexible sheet and a semi-rigid sheet that are sealed along their edges to form a closed pocket or reservoir for containing a volatile fluid. The semi-rigid sheet is sealed on a first side to a flexible sheet and sealed on a second side to a vapor permeable membrane. The semi-rigid sheet contains a volatile fluid in the reservoir during storage, preventing contact of the volatile fluid with the vapor permeable membrane before the device is activated. The semi-rigid sheet has a differential score to guide the bounds of an opening that is formed upon activation. Once activated, the vapor permeable membrane provides continuous emission of a volatile fluid from the device.

FIELD OF THE INVENTION

The present invention relates to a device for delivering a volatilefluid to the atmosphere in a continuous manner. More specifically, thepresent invention relates to a low-cost, single-use, portable devicehaving a vapor permeable membrane for continuously delivering, over aperiod time and without leakage, a volatile fluid to the atmosphere.

BACKGROUND OF THE INVENTION

It is generally known to use a device to evaporate a volatile fluid intoa space to deliver a variety of benefits, such as air freshening orreducing malodors. Non-energized systems, for example, systems that arenot powered by electrical energy, are a popular way for the delivery ofvolatile fluids to the atmosphere.

US 2010/0308126A1 to The Procter & Gamble Company offers a deliveryengine having a reservoir, a rupturable substrate, vapor permeablemembrane sealed to the reservoir, and a rupture tab positioned betweenthe rupturable substrate and the vapor permeable membrane. To breach therupturable substrate and activate the delivery engine, the rupture tabis compressed perpendicularly to the plane of the rupturable substrateby a user's hand or by insertion of the delivery engine into a housing.Such configuration of the rupture tab may add bulk to the deliveryengine, add production/shipping costs, and require additional protectivepackaging to prevent premature rupture. Additionally, where athermoformed reservoir is used, a horizontal indexing operationinvolving thermoforming, filling, and sealing is required to avoid fluidspills from the thermoform during production. This may result in limitedthroughput processing.

U.S. Pat. No. 8,069,985 to Diapack Ltd. offers a sealed, single-dose,break-open package for containing a product, such as shampoo. Thepackage includes a semi-rigid plastic material and a flexible plasticsheet that is sealed to the semi-rigid plastic material along theirperimeters, forming a pocket for containing a dose of product. Thesemi-rigid plastic material has an incision that varies in depth toguide controlled breakage and form an outlet from which the contentsexit the package. A potential issue in using this type of break-openpackage for continuously delivering a volatile fluid over a period oftime is adding a vapor permeable membrane that forms a leak-proof sealbetween the vapor permeable membrane and the semi-rigid plasticmaterial, at least while the volatile fluid is being emitted to a space.Another potential issue is designing an incision on the semi-rigidplastic material that prevents a volatile fluid from leaking through theincision prior to activation, and prevents the incision from breakinginto a sealed edge (i.e. edge where the barrier layer is sealed to thereservoir) and leaking after the device is activated

As such, there exists a need for a low cost, single-use, portable devicehaving a vapor permeable membrane for continuously delivering, over aperiod time and without leakage, a volatile fluid to the atmosphere.

SUMMARY OF THE INVENTION

According to one embodiment of the invention, there is provided a devicefor delivering a volatile fluid, wherein said device comprises anx-axis, a y-axis, a z-axis, and a sealed edge, wherein said devicefurther comprises a flexible sheet; a multi layer semi-rigid sheetsealed to said flexible sheet to form a reservoir, wherein saidsemi-rigid sheet comprises a structural layer, a differential scoredefining a scored region and an un-scored region, wherein saiddifferential score comprises at least one incision having a depth alongsaid z-axis that transverses at least about 50% of said structurallayer, and wherein said un-scored region is about 5 mm to about 15 mmfrom said sealed edge; and a vapor permeable membrane sealed to saidsemi-rigid sheet.

According to another embodiment of the invention, there is provided adevice for delivering a volatile fluid wherein said device comprises anx-axis, a y-axis, a z-axis, and wherein said device further comprises areservoir for containing a volatile fluid. The device also comprises amulti layer semi-rigid sheet comprising a first sealant layer sealed tosaid reservoir; a barrier layer sealed to said first sealant layer; astructural layer sealed to said barrier layer; optionally, a secondsealant layer sealed to said structural layer; wherein said multi layersemi-rigid sheet further comprises a differential score comprising anupper incision and a lower incision, said upper incision has a depthalong said z-axis that transverses at least about 50% of said structurallayer and said lower incision transverses at least about 50% of saidfirst sealant layer. The device also comprises a vapor permeablemembrane heat-sealed to said semi-rigid sheet.

According to yet another embodiment of the invention, there is provideda device for delivering a volatile fluid wherein said device comprisesan x-axis, a y-axis, a z-axis, and a sealed edge, and wherein saiddevice further comprises a flexible sheet. The device also comprises amulti layer semi-rigid sheet sealed to said flexible sheet to form areservoir for containing a perfume mixture. The multi layer semi-rigidsheet comprises a first sealant layer heat-sealed to said flexiblesheet, wherein said first sealant layer comprises a material selectedfrom the group consisting of polyethylene, polypropylene, polyethyleneterpthalate, and combinations thereof, and wherein said first sealantlayer has a thickness along said z-axis of at least about 15 microns; aperfume resistant barrier layer sealed to said first sealant layer,wherein said barrier layer comprises a material selected from the groupconsisting of polyethylene, ethylene vinyl alcohol, and combinationsthereof, and wherein said barrier layer comprises a thickness along saidz-axis from about 10 microns to about 15 microns; a structural layersealed to said perfume resistant barrier layer, wherein said structurallayer comprises a plastic selected from the group consisting ofpolystyrene, polyvinyl chloride, acrylonitrile butadiene styrene,polypropylene, polyethylene, polyethylene terpthalate, and combinationsthereof, and wherein said barrier layer comprises a thickness along saidz-axis of about 350 microns; a differential score defining a scoredregion and an un-scored region, wherein said differential scorecomprises at least one incision having a depth along said z-axis thattransverses at least about 50% of said structural layer, and whereinsaid un-scored region is about 5 mm to about 15 mm from said sealededge; and, optionally, a second sealant layer heat-sealed to saidstructural layer and consisting of polyethylene, polypropylene,polyethylene terpthalate, and combinations, wherein said second sealantlayer comprises a thickness along said z-axis of at least about 15 ums,and wherein said differential score fully transverses said secondsealant layer. The device also comprises a microporous membraneheat-sealed to said semi-rigid sheet.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with the claims particularly pointingout and distinctly claiming the invention, it is believed that thepresent invention will be better understood from the followingdescription taken in conjunction with the accompanying drawings inwhich:

FIG. 1 shows a cut-away perspective view of an embodiment of a deviceaccording to the present invention;

FIG. 2 shows a cross-sectional view, taken along lines 2-2 of the devicein FIG. 1;

FIG. 3 shows an enlarged portion of the semi-rigid sheet 30 and thescore 40, shown in FIG. 2;

FIG. 4 shows an embodiment of the device, according to the presentinvention, with an intensity control sheet;

FIG. 5A shows a cut-away rear elevational view of a device, according tothe present invention, surrounded by a housing;

FIG. 5B shows a cut-away rear perspective view of the device and housingin FIG. 5A in an activated, upright configuration.

DETAILED DESCRIPTION OF THE INVENTION

The device comprises, consists essentially of, or consists of, variouscombinations of the materials, features, structures, and/orcharacteristics described herein.

The device of the present invention is suitable for purposes ofproviding fragrances, air fresheners, deodorizers, odor eliminators,malodor counteractants, insecticides, insect repellants, medicinalsubstances, disinfectants, sanitizers, mood enhancers, and aromatherapyaids, or for any other purpose using a volatile fluid that acts tocondition, modify, or otherwise change the atmosphere or theenvironment.

Referring to FIGS. 1 and 2, a device 10 in accordance with oneembodiment of the present invention is shown. The device 10 includes aflexible sheet 20, a semi-rigid sheet 30 having a score 40, and a vaporpermeable membrane 50. The semi-rigid sheet 30 has a first side 33 thatis sealed to the flexible sheet 20 along the device's periphery, forminga closed pouch or reservoir 60. This sealed periphery of the device 10is referred to herein as the “edge” 15 and may be about 5 mm in width.While one reservoir 60 is shown in FIG. 2, a plurality of reservoirs,formed by sealing off a plurality of pouches with the flexible sheet 20and semi-rigid sheet 30, may also be provided. The semi-rigid sheet 30is sealed along the edge 15 on a second side 39 to a vapor permeablemembrane 50. The semi-rigid sheet 30 contains a volatile fluid in thereservoir 60, preventing contact of the volatile fluid with the vaporpermeable membrane 50 before the device 10 is activated. The semi-rigidsheet 30 has a differential score 40 to guide the boundary of an openingthat is formed upon activation of the device 10. Once activated, thevapor permeable membrane 50 provides continuous emission of a volatilefluid from the device 10. The continuous emission of a volatile fluidcan be of any suitable length, including but not limited to, up to: 20days, 30 days, 60 days, 90 days, 120 day or any period between 30 to 120days, without leakage.

The term “volatile fluid” as used herein, refers to a material that isvaporizable at room temperature and atmospheric pressure without theneed of an energy source. The volatile fluid may be a compositioncomprised entirely of a single volatile fluid. The volatile fluid mayalso be a composition comprised entirely of a volatile fluid mixture(i.e. the mixture has more than one volatile component). Further, it isnot necessary for all of the component materials of the composition tobe volatile. Any suitable volatile fluid in any amount or form,including a liquid or emulsion, may be used.

Volatile fluid suitable for use herein may, thus, also have non-volatilecomponents, such as carrier materials (e.g., water, solvents, etc). Itshould also be understood that when the volatile fluid is describedherein as being “delivered” or “emitted”, this refers to thevolatilization of the volatile component thereof, and does not requirethat the non-volatile components thereof be emitted.

The device 10 may be compact and easily portable (e.g. sized to fit in aclothing pocket, wallet, purse, etc.). Although FIGS. 1-4 show astand-alone device, it is contemplated that the device 10 may be usedwith known diffusion assistance means, such as heaters and fans, todeliver volatile fluids to the atmosphere.

The device 10 includes a width, length, and depth along an x-axis,y-axis, and z-axis, respectively. The device 10 may be elongate in thatits length to width ratio is about 2:1 to about 4:1, alternatively about1.5:1 to about 2.5:1. The device 10 may have a length of about 45 mm toabout 55 mm, alternatively about 51 mm; a width of about 15 mm to about30 mm to about, alternatively about 23 mm; a depth of about 5 mm toabout 15 mm, alternatively about 11 mm. The dimensions of the reservoir60 may be such that it holds about 2 ml to about 30 ml, alternativelyabout 2 ml to about 10 ml, alternatively about 2 ml to about 8 ml,alternatively about 4 ml to about 6 ml, alternatively about 2 ml,alternatively about 6 ml of volatile fluid.

Flexible Sheet

The device 10 includes a flexible sheet 20 that is sealable to thesemi-rigid sheet 30 and is a significant barrier to both liquid andvaporous volatile material. Having a flexible pouch type reservoirenables production of the device 10 on a high throughput, morecost-effective vertical form, fill, and seal process.

The flexible sheet 20 is made of a material that provides sufficientflexibility to bend with the semi-rigid sheet 30 and breach thedifferential score 40 in the semi-rigid sheet 30. Flexible sheetmaterials are known in the art, and may comprise polyethylene (“PE”),polyethylene terpthalate (“PET”), metallized PET, aluminum (“ALU”),oriented polypropylene (“OPP”), oriented polyamide (“OPA”),polyacrylonitrile (e.g. Barex™), ethylene vinyl alcohol (“EVOH”), andcombinations or laminates thereof.

Table 1 shows the possible material blends and thickness combinations ofthe flexible sheet.

TABLE 1 Type of laminate Thickness (microns) PET/PE PET 12-30/PE 20-150PET/EVOH/PE PET 12-30/EVOH 15-20/PE 30-150 PET/ALU/PE PET 12-30/ALU6-30/PE 20-150 OPP/ALU/PE OPP 15-30/ALU 6-30/PE 20-150 OPA/ALU/PE OPA15-30/ALU 6-30/PE 20-150

Semi-Rigid Sheet

The device 10 also includes a multi-layer semi-rigid sheet 30 that isheat-sealable on both sides. Referring to FIG. 3, the semi-rigid sheet30 comprises a first sealant layer 32 having a first side 33 that isheat-sealable to the flexible sheet 20, a barrier layer 34, a structurallayer 36, and a second sealant layer 38 having a second side 39 that isheat-sealable to a vapor permeable membrane 50. Perfume resistant tielayers may be included between each layer of the semi-rigid sheet 30.Each tie layer comprises water-based or organic solvent-basedpolyurethane, polyurea, ethylene acrylic acid, PE, polypropylene (“PP”),maleic anhydride, or other organic chemical resistant compounds. In someembodiments, the tie layer comprises polyurethane.

First sealant layer 32 is heat-sealable to the flexible sheet 20. Firstsealant layer 32 may be made of any material that is heat-sealable toits adjacent layer. In the embodiment shown in FIG. 3, the adjacentlayer is the flexible sheet 20. First sealant layer 32 may comprises PE,PP, PET, or combinations thereof. Adjacent layer (e.g. flexible sheet20) may be made of the same material as the first sealant layer 32. Forexample, where the first sealant layer 32 is PE, the flexible sheet 20is also made of PE. First sealant layer 32 has a thickness along thez-axis ranging from about 15 microns to about 300 microns, alternativelyfrom about 15 microns to about 200 microns, alternatively from about 15microns to about 100 microns, alternatively from about 15 microns toabout 50 microns, alternatively about 35 microns, alternatively about 20microns.

The barrier layer 34 can be made of any material that ruptures withapplied force, with or without the presence of an element to aid in suchrupture. Because the barrier layer 34 is intended to contain a volatilefluid while in storage, it may be made from a material which ischemically resistant to volatile fluids, including perfumes andsolvents, and prevents evaporation of the volatile fluid prior to itsintended use. Such materials may be impermeable to vapors and liquids.Suitable materials for the barrier layer 34 include a flexible film,such as a polymeric film, a flexible aluminum or metal foil, or acomposite material such as foil/polymeric film laminate. Suitableflexible foils include a 20 micron aluminum foil. Suitable polymericfilms include PET films, acrylonitrile copolymer barrier films such asthose sold under the tradename Barex® by INOES, chlorotrifluoroethylene(e.g. Aclar™), EVOH, and combinations thereof. It is also contemplatedthat coated barrier films may be utilized as a barrier layer. Suchcoated barrier films include metalized PET, metalized PP, silica oralumina coated film may be used. Any barrier material, whether coated oruncoated, may be used alone and or in combination with other barriermaterials.

Barrier layer 34 has a thickness that is sufficient to serve as aperfume barrier during normal storage times yet thin enough to breakopen when the device 10 is activated. Suitable thicknesses in thez-direction include about 5 microns to about 30 microns, alternativelyabout 5 microns to about 15 microns. The thickness of the barrier layerwill vary depending on the material of choice. Where aluminum foil isused, for example, the thickness may be about 20 to about 25 microns.

In some embodiments, the semi-rigid sheet 30 may include a second orsupplemental barrier layer (not shown) akin to barrier layer 34. In suchcase, the supplemental barrier layer may be heat-sealable to the firstside 33 and the flexible sheet 20 to provide supplemental protection andhelp prevent fluid in the reservoir 60 from passing through thedifferential score 40 while in storage.

Structural layer 36 may comprise one of the following materials:polystyrene (PS), polyvinyl chloride (“PVC”), acrylonitrile butadienestyrene (“ABS”), PET, PE, PP, nylon, nylon composites, or combinationsthereof. In one embodiment, the structural layer is made of PET or PP orcombinations thereof. Structural layer 36 may have a thickness along thez-axis that ranges from about 200 microns to about 750 microns,alternatively from about 300 microns to about 750 microns, alternativelyfrom about 350 microns to about 700 microns, alternatively from about300 microns to about 450 microns, alternatively from about 300 micronsto about 400 microns, alternatively from about 300 microns to about 350microns.

Table 2 shows suitable material blends and thickness combinations of thestructural layer 36.

TABLE 2 Type of laminate Thickness (microns) PS/PE PS 300-700/PE 20-50PS/PP PS 300-700/PP 20-50 PVC/PE PVC 300-700/PE 20-50 ABS/PE ABS300-700/PE 20-50 PP/PE PP 300-700/PE 20-50

The semi-rigid sheet 30 also includes a second sealant layer 38 having asecond side 39 that is heat-sealable to the vapor permeable membrane 50.Second sealant layer 38 may be made from PE, PP, or combinationsthereof. Suitable thicknesses for the second sealant layer 38, along thez-axis, range from about 15 microns to about 300 microns, alternativelyfrom about 15 microns to about 200 microns, alternatively from about 15microns to about 100 microns, alternatively from about 15 microns toabout 50 microns, alternatively from about 20 microns to about 50microns, alternatively from about 35 microns, alternatively about 20microns.

In some embodiments, the semi-rigid sheet 30 comprises a first sealantlayer 32 of about 35 micron thick PE, a barrier layer 34 of about 10micron thick EVOH, a structural layer 36 of about 450 micron thick PS,and a second sealant layer 38 of about 35 micron thick PE. Thus, thesemi-rigid sheet may have a total thickness of about 530 microns, atypical weight of about 500 g/m2, a typical break load of about 16N/mm2, and a typical modulus of elasticity of about 1500 to about 3500,alternatively about 2200 N/mm2. In other embodiments, the semi-rigidsheet 30 comprises a combined second sealant layer and structural layerof about 200 micron PP, 10 micron EVOH barrier layer, and a 200 micronPP first sealant layer. In other embodiments, the semi-rigid sheet 30comprises 50 micron PE second sealant layer, 350 micron PET structurallayer, 20 micron PE/10 micron EVOH barrier layer, and 20 micron PE firstsealant layer.

The semi-rigid sheet 30 includes at least one differential score 40 onthe x-y plane. “Differential score” means a score having an incisiondepth that varies along the length of the incision along the x-axis (ory-axis in some embodiments) of the semi-rigid sheet 30. The differentialscore 40 may run along the x-axis or, in some embodiments, along they-axis. The differential score 40 does not run the across the entirelength of the x-axis (i.e. width of the device 10). Rather, thedifferential score 40 is positioned between the edge 15 so that thedifferential score 40 terminates prior to meeting the sealed edge 15 ofthe device (i.e. where the semi-rigid sheet 30 is sealed to the flexiblesheet 20 and the vapor permeable membrane 50). The region(s) of thesemi-rigid sheet 30 having a differential score 40 is considered thescored region(s) 44. The regions of the semi-rigid sheet 30 extendingfrom the ends of the differential score 40 (i.e. along the same axis asa differential score or in-line with the differential score) areconsidered the un-scored regions 46.

The device 10 may comprises more than one differential score arranged inany format on the x-y plane to facilitate breaching the structural layer36, yet not breaching the sealed edge 15. In some embodiments, thedevice 10 may include two intersecting differential scores (i.e. twoincisions that intersect one another along the x-y plane. Further, thedevice 10 may include such intersecting differential score pattern onthe first side 33 and second side 39 of the semi rigid sheet 30.

The un-scored regions 46 of the semi-rigid sheet 30 are from about 5 mmto about 15 mm, alternatively from about 5 mm to about 10 mm,alternatively about 5 mm from the sealed edge 15. The material of thesemi-rigid sheet 30 may affect the distance of the differential scorealong the x-axis (e.g. higher modulus may require greater amount ofun-scored region). Creating a differential score 40 that is too close tothe edge 15 may risk breaking the sealed edge 15, resulting in leakageof the fluid. Creating a differential score 40 that is greater than 15mm from the edge 15 may prevent sufficient quantities of volatile fluidfrom contacting the vapor permeable membrane 50, limiting delivery ofvolatile fluids to the atmosphere.

The cross-sectional form of the differential score 40 may take onvarious shapes. It may be curved (e.g. in the form of an arc of a circleor an arc of an ellipse), or may be V-shaped as shown in FIG. 3,U-shaped, L-shaped, or combinations thereof. In some embodiments,differential score 40 may be inclined (i.e. may slope with respect tothe sides of the semi-rigid sheet 30).

Differential score 40 may comprise a single upper incision 41 or anupper incision 41 and a lower incision 42. The upper and lower incisionsdo not transverse the barrier layer 34. More specifically, the upper andlower incisions are deepest along a central portion of the differentialscore 40. In other words, breakage along differential score 40 is alwaysgradual (i.e. proportional to the extent to which device 10 is bent), sothat, when device 10 is bent relatively lightly, the semi-rigid sheet 30only breaks along the central portion of the differential score 40. And,as device 10 is bent further, breakage of the semi-rigid sheet 30 alsoextends to the peripheral portions of the differential score 40.

The depth of the upper incision 41, along the z-axis as shown in FIG. 3,transverses the thickness of the second sealant layer 38 and from about40% to about 100%, alternatively from about 50% to about 100%,alternatively from about 50% to about 90%, alternatively from about 60%to about 100%, alternatively from about 70% to about 100%, alternativelyat least about 50% of the depth of the structural layer 36. The depth ofthe lower incision 42, in the z-direction, transverses a portion ortraverses the entire first sealant layer 32. The depth of the lowerincision 42 transverses from about 50% to about 100%, alternatively fromabout 50% to about 90%, alternatively about 65%, alternatively about 80%of the depth of the first sealant layer 32.

Where a semi-rigid sheet comprises 50 micron PE/350 micron PET/20 micronPE/10 micron EVOH/20 micron PE, the maximum depth of the upper incision41 may be 420 microns through the PE/PET/PE layers and the maximum depthof the lower incision 42 may be 20 microns through the last PE layer.Where a semi-rigid sheet comprises 200 micron PP/10 micron EVOH/200micron PP, the maximum depth of the differential score 40 may be 200microns for either upper or lower incision; the other incision having amaximum depth of less than 200 microns.

Vapor Permeable Membrane

A vapor permeable membrane 50 is sealed to the edge 15 of the secondside 39 of the second sealant layer 38 such that the vapor permeablemembrane 50 is on the outside of the device 10 and exposed to theatmosphere. A vapor permeable membrane will prevent volatile fluid fromleaking from the device 10 while allowing volatile vapor to exit thedevice 10. The vapor permeable membrane 50 is sufficiently flexible towithstand flexion of the device 10 when the semi-rigid sheet 30 is beingbreached. The vapor permeable membrane 50 also prevents free flow offluid out of the vapor permeable membrane 50, thus addressing leakageproblems.

While not wishing to be bound by theory, the physical characteristics ofa membrane may affect the diffusion or transfer rate of volatile fluidsthrough the vapor permeable membrane 50. Such characteristics mayinclude materials used, use of fillers, pore size, thickness, andevaporative surface area. Suitable vapor permeable membranes for thepresent invention include an ultra high molecular weight polyethylene(UHMWPE) type membrane optionally filled with silica as described in US2010/0308126A1. Such UHMWPE membranes include Daramic™ V5, availablefrom Daramic; Solupor®, available from DSM (Netherlands); Teslin™SP1100HD, available from PPG Industries; and combinations thereof. It isbelieved that these membranes flex and allow a volatile fluid to freelydissipate while containing fluid within the device 10. Other vaporpermeable membranes include traditional PE, PP, ethylene vinyl acetate,and combinations thereof.

In one aspect of the invention, the vapor permeable membrane 50 mayinclude a dye that is sensitive to the amount of volatile fluid it is incontact with to indicate end-of-life. Alternatively, the membrane 50 maychange to transparent when in contact with a fragrance or volatile fluidto indicate diffusion is occurring. Other means for indicatingend-of-life that are known in the art are contemplated for the presentinvention.

The vapor permeable membrane 50 may have a thickness along the z-axis,of about 0.01 mm to about 1 mm, alternatively from about 0.1 mm to 0.4mm, alternatively from about 0.15 mm to about 0.35 mm, alternativelyabout 0.25 mm.

Those of ordinary skill in the art will appreciate that the surface areaof the membrane 50 can vary depending on the user preferred size of thedevice 10. In some portable embodiments, the evaporative surface area ofthe membrane may be about 2 cm² to about 100 cm², alternatively about 2cm² to about 35 cm², alternatively about 10 cm² to about 50 cm²,alternatively about 10 cm² to about 45 cm², alternatively about 10 cm²to about 35 cm², alternatively about 15 cm² to about 40 cm²,alternatively about 15 cm² to about 35 cm², alternatively about 20 cm²to about 35 cm², alternatively about 30 cm² to about 35 cm²,alternatively about 35 cm² to 40 cm².

The vapor permeable membrane 50 may be secured to the second side 39 ofthe second sealant layer 38 along the edge 15 by a layer of adhesives,heat and/or pressure sealing, ultrasonic bonding, crimping, and the likeor a combination thereof. Once breached, the volatile fluid flows out ofthe reservoir 60, through the semi-rigid sheet 30, contacting the vaporpermeable membrane 50, and is then delivered to the atmosphere. Becausethe vapor permeable membrane 50 is shielded from the volatile fluiduntil the semi-rigid sheet 30 is breached, the fragrance intensity maybuild slowly from zero to its equilibrium rate of release when the vaporpermeable membrane 50 is fully wetted.

Depending on the final configuration of the device 10, additional partsmay be added. Such parts may serve the purpose of, for example,providing intensity control or protection from contamination, dust, andthe like during shipment.

Referring to FIG. 4, the device 10 may include an intensity controlsheet 80. The intensity control sheet 80 may be made of any materialthat slows diffusion of a volatile composition from the device 10. Theintensity control sheet 80 may also be made from a printable materialavailable in the art to print user instructions, decorative artwork, orthe like. The intensity control sheet 80 may be heat-sealed, crimped,bonded or otherwise attached to the vapor permeable membrane 50. In theembodiment shown in FIG. 4, the intensity control sheet 80 includes asingle opening to reveal the vapor permeable membrane 50 and includes acover 82. The cover 82 can be opened or closed in varying degrees by auser to control the intensity of the volatile fluid from the reservoir60 to the atmosphere.

In other embodiments, the intensity control sheet 80 may have adjustablevents or apertures. For example, the intensity control sheet 80 maycomprises a vented layer having one or more vents and an unvented layerpositioned over the vents. The vented or the unvented layer may slide orpivot to reveal the vents and allow intensity control of the volatilefluid from the reservoir 60 to the atmosphere. Increasing the size ofthe vents, may increase the delivery of volatile fluid. Opening of thevents can be controlled by the user through a variety of means. A usermay open, partially open, partially close, or close the vents.

Referring to FIGS. 5A and 5B, the device 10 may also include a housing90 that serves as an intensity control feature and as an upright standfor the device 10. The housing 90 can also serve as the outer packagingof the device 10 for transport and display in a retail location. Thehousing 90 may be made from any commercially available materialincluding paper, cardboards and plastics.

The housing 90 may be made from a single panel that circumferences thedevice 10 and is secured on one side as shown in FIGS. 5A and 5B. Thehousing 90 may also be formed with multiple panels secured together withan adhesive or the like in any configuration to surround, at least inpart, the device 10. During transport and/or prior to activation of thedevice, the housing may be in a flat configuration as shown in FIG. 5A.The housing may include an opening 92 for hanging from a display hook ata retail location. The housing 90 may define a window 94 that shows thedevice to the user. The window 94 may comprise a transparent sheetrevealing the flexible sheet 30 or the window 94 may be an unobstructedopening in the housing 90. In some embodiments, the housing 90 does notinclude a window 94.

The device 10 may include a tab 96 extending therefrom. The device 10 isactivated and set upright in one step by creating an approximate 90degree bend in the device to breach the score 40. This can be done bypushing the tab 96 side of the device towards a notch 98 in the housing10 as shown in FIG. 5B. In FIG. 5B, the approximate 90 degree bend iscreated on the side of the vapor permeable membrane 50. Once bent, thetab 96 is inserted into the notch 98. In this way, the tab 96 locks intothe notch 98 to stand the device 10 in an upright position whilefacilitating delivery of the volatile fluid to the atmosphere.

Volatile Fluid

The volatile fluid can be in the form of perfume oil. Most conventionalfragrance materials are volatile essential oils. The volatile fluid canbe a volatile organic compound commonly available from perfumerysuppliers. Furthermore, the volatile fluid can be synthetically ornaturally formed materials. Examples include, but are not limited to:oil of bergamot, bitter orange, lemon, mandarin, caraway, cedar leaf,clove leaf, cedar wood, geranium, lavender, orange, origanum,petitgrain, white cedar, patchouli, neroili, rose absolute, and thelike. In the case of air freshener or fragrances, the different volatilefluids can be similar, related, complementary, or contrasting.

The volatile fluid may also originate in the form of a crystallinesolid, which has the ability to sublime into the vapor phase at ambienttemperatures or be used to fragrance a liquid. Any suitable crystallinesolid in any suitable amount or form may be used. For example, suitablecrystalline solids include but are not limited to: vanillin, ethylvanillin, coumarin, tonalid, calone, heliotropene, musk xylol, cedrol,musk ketone benzohenone, raspberry ketone, methyl naphthyl ketone beta,phenyl ethyl salicylate, veltol, maltol, maple lactone, proeugenolacetate, evemyl, and the like.

It may not be desirable, however, for volatile fluids to be closelysimilar if different volatile fluids are being used in an attempt toavoid the problem of emission habituation. Otherwise, the peopleexperiencing the emissions may not notice that a different material isbeing emitted. The different emissions can be provided using a pluralityof delivery systems each providing a different volatile fluid (such as,musk, floral, fruit emissions, etc). The different emissions can berelated to each other by a common theme, or in some other manner. Anexample of emissions that are different, but complementary might be acinnamon emission and an apple emission.

In addition to the volatile fluid of the present invention, the device10 may include any known malodor composition to neutralize odors.Suitable malodor compositions include cyclodextrin, reactive aldehydesand ionones.

The composition may be formulated such that the composition comprises avolatile fluid mixture comprising about 10% to about 100%, by totalweight, of volatile fluids each having a VP at 25° C. of less than about0.01 torr; alternatively about 40% to about 100%, by total weight, ofvolatile fluids each having a VP at 25° C. of less than about 0.1 torr;alternatively about 50% to about 100%, by total weight, of volatilefluids each having a VP at 25° C. of less than about 0.1 torr;alternatively about 90% to about 100%, by total weight, of volatilefluids each having a VP at 25° C. of less than about 0.3 torr. In oneembodiment, the volatile fluid mixture may include 0% to about 15%, bytotal weight, of volatile fluids each having a VP at 25° C. of about0.004 torr to about 0.035 torr; and 0% to about 25%, by total weight, ofvolatile fluids each having a VP at 25° C. of about 0.1 torr to about0.325 torr; and about 65% to about 100%, by total weight, of volatilefluids each having a VP at 25° C. of about 0.035 torr to about 0.1 torr.One source for obtaining the saturation vapor pressure of a volatilefluid is EPI Suite™, version 4.0, available from U.S. EnvironmentalProtection Agency.

The viscosity of a volatile fluid may control how and when a volatilefluid is delivered to the vapor permeable membrane 50. For example, lessviscous compositions may flow faster than the more viscous volatilefluids. Thus, the membrane may be first wetted with the less viscousmaterials. The more viscous volatile fluid, being slightly less or ofsimilar density with the less viscous phase, may remain in the reservoirvia gravity. Thus, the less viscous volatile fluid may be delivered tothe vapor permeable membrane 50 and emitted to the atmosphere morequickly. To help prevent liquid from seeping through the vapor permeablemembrane 40, volatile fluids may have viscosities less than about 23 cPand surface tension less than about 33 mN/m.

In one embodiment, the composition containing a volatile fluid may havea viscosity of about 1.0 cP to less than about 25 cP, alternativelyabout 1.0 cP to less than about 23, alternatively about 1.0 cP to lessthan about 15 cP.

The composition containing a volatile fluid may be designed such thatthe composition may include a surface tension of about 19 mN/m to lessthan about 33 mN/m, alternatively about 19 mN/m to less than about 30mN/m, alternatively about 19 mN/m to less than about 27 mN/m.

As used in this specification and the appended claims, the singularforms “a”, “an”, and “the” include plural references unless the contentclearly dictates otherwise. Thus, for example, “a volatile fluid” mayinclude more than one volatile fluid

Every numerical range given throughout this specification will includeevery narrower numerical range that falls within such broader numericalrange, as if such narrower numerical range were all expressly writtenherein. For example, a stated range of “1 to 10” should be considered toinclude any and all subranges between (and inclusive of) the minimumvalue of 1 and the maximum value of 10; that is, all subranges beginningwith a minimum value of 1 or more and ending with a maximum value of 10or less, e.g., 1 to 6.1, 3.5 to 7.8, 5.5 to 10, etc.

Further, the dimensions and values disclosed herein are not to beunderstood as being strictly limited to the exact numerical valuesrecited. Instead, unless otherwise specified, each such dimension isintended to mean both the recited value and a functionally equivalentrange surrounding that value. For example, a dimension disclosed as “40mm” is intended to mean “about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed:
 1. A device for delivering a volatile fluid, whereinsaid device comprises an x-axis, a y-axis, a z-axis, and a sealed edge,wherein said device further comprises: a. a flexible sheet; b. a multilayer semi-rigid sheet sealed to said flexible sheet to form areservoir, wherein said semi-rigid sheet comprises: i. a structurallayer, ii. a differential score defining a scored region and anun-scored region, wherein said differential score comprises at least oneincision having a depth along said z-axis that transverses at leastabout 50% of said structural layer, and wherein said un-scored region isabout 5 mm to about 15 mm from said sealed edge; and c. a vaporpermeable membrane sealed to said semi-rigid sheet.
 2. The device ofclaim 1, wherein said un-scored region is about 5 mm to about 10 mm fromsaid sealed edge.
 3. The device of claim 1, wherein said semi-rigidsheet further comprises a first sealant layer, and wherein saiddifferential score comprises an upper incision and a lower incision,wherein said lower incision has a depth, along said z-axis, thattransverses at least 50% of said first sealant layer.
 4. The device ofclaim 1, wherein said semi-rigid sheet further comprises a secondsealant layer sealed to said structural layer and to said vaporpermeable membrane, wherein said second sealant layer comprises amaterial selected from the group consisting of polyethylene,polypropylene, and combinations thereof.
 5. The device of claim 1,wherein said semi-rigid sheet further comprises a perfume resistantbarrier layer sealed to said structural layer and comprising a materialselected from the group consisting of: ethylene vinyl alcohol, metalfoil, and combinations thereof.
 6. The device of claim 1, wherein saidsemi-rigid sheet comprises at least 3 materials selected from the groupconsisting of: polyethylene, polyethylene terpthalate, ethylene vinylalcohol, polypropylene, polystyrene, and combinations thereof.
 7. Thedevice of claim 1, wherein said semi-rigid sheet comprises polyethylene,ethylene vinyl alcohol, and polypropylene.
 8. The device of claim 1,wherein said structural layer comprises about 200 micron thickpolypropylene, and wherein said semi-rigid sheet further comprises afirst sealant layer of about 200 micron thick polypropylene, a barrierlayer of about 10 micron thick ethylene vinyl alcohol, and a secondsealant layer of about 35 microns.
 9. The device of claim 1, whereinsaid semi-rigid sheet has a modulus of elasticity of about 2200 N/mm2.10. The device of claim 1, wherein said device further comprises avolatile fluid mixture contained in said reservoir, wherein saidvolatile fluid mixture comprises about 90% to about 100%, by totalweight, of volatile fluids each having a VP at 25° C. of less than about0.3 torr.
 11. The device of claim 1, wherein said device furthercomprises a perfume mixture contained in said reservoir.
 12. The deviceof claim 1, wherein said vapor permeable membrane is a microporousmembrane comprising an average pore size of about 0.01 to about 0.03microns.
 13. The device of claim 12, wherein said vapor permeablemembrane comprises an average pore size of about 0.02 microns.
 14. Thedevice of claim 1, wherein the evaporative surface area of said vaporpermeable membrane is about 2 cm² to about 35 cm²
 15. The device claim 1further comprising an intensity control sheet attached to said vaporpermeable membrane.
 16. The device of claim 1, wherein said device iscontained in a housing.
 17. The device of claim 16, wherein said housingcomprises a notch, and wherein said device further comprises a tabextending from said device, said tab is configured to insert into saidnotch.
 18. A device for delivering a volatile fluid, wherein said devicecomprises an x-axis, a y-axis, a z-axis, and wherein said device furthercomprises: a. a reservoir for containing a volatile fluid; b. a multilayer semi-rigid sheet comprising: i. a first sealant layer sealed tosaid reservoir, ii. a barrier layer sealed to said first sealant layer,iii. a structural layer sealed to said barrier layer, iv. optionally, asecond sealant layer sealed to said structural layer, wherein said multilayer semi-rigid sheet further comprises a differential score comprisingan upper incision and a lower incision, said upper incision has a depthalong said z-axis that transverses at least about 50% of said structurallayer and said lower incision has a depth along said z-axis thattransverses at least about 50% of said first sealant layer; and c. avapor permeable membrane heat-sealed to said semi-rigid sheet.
 19. Thedevice of claim 18, wherein said lower incision has a depth, along saidz-axis, that transverses at least 50% of said first sealant layer.
 20. Adevice for delivering a volatile fluid, wherein said device comprises anx-axis, a y-axis, a z-axis, and a sealed edge, and wherein said devicefurther comprises: a. a flexible sheet; b. a multi layer semi-rigidsheet sealed to said flexible sheet to form a reservoir for containing aperfume mixture, wherein said semi-rigid sheet comprises: i. a firstsealant layer heat-sealed to said flexible sheet, wherein said firstsealant layer comprises a material selected from the group consisting ofpolyethylene, polypropylene, polyethylene terpthalate, and combinationsthereof, and wherein said first sealant layer has a thickness along saidz-axis of at least about 15 microns, ii. a perfume resistant barrierlayer sealed to said first sealant layer, wherein said barrier layercomprises a material selected from the group consisting of polyethylene,ethylene vinyl alcohol, and combinations thereof, and wherein saidperfume resistant barrier layer comprises a thickness along said z-axisfrom about 10 microns to about 15 microns; iii. a structural layersealed to said perfume resistant barrier layer, wherein said structurallayer comprises a plastic selected from the group consisting ofpolystyrene, polyvinyl chloride, acrylonitrile butadiene styrene,polypropylene, polyethylene, polyethylene terpthalate, and combinationsthereof, and wherein said structural layer comprises a thickness alongsaid z-axis from about 350 microns to about 700 microns; iv. adifferential score defining a scored region and un-scored regions,wherein said differential score comprises at least one incision having adepth along said z-axis that transverses at least about 50% of saidstructural layer, and wherein said un-scored regions are about 5 mm toabout 15 mm from said sealed edge; and v. optionally, a second sealantlayer heat-sealed to said structural layer comprising a materialselected from the group consisting of polyethylene, polypropylene,polyethylene terpthalate, and combinations, and wherein, when saidsecond sealant layer is present, said second sealant layer comprises athickness along said z-axis of at least about 15 microns, and whereinsaid differential score fully transverses said second sealant layer; andc. a microporous membrane heat-sealed to said semi-rigid sheet.